Allen-Bradley Guardmaster GuardLink User manual

Guardmaster GuardLink Safety System

Catalog Numbers 440R-DG2R2T (DG Safety Relay); 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D (Taps);

898D-418U-DM2 (Terminator); 440S-GLTAPBRKx (Bracket); 440R-ENETR (EtherNet/IP Network Interface)

User Manual

Original Instructions

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are

required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may

be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from

the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and

requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or

software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Labels may also be on or inside the equipment to provide specific precautions.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 3

Table of Contents

Preface

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

Overview What Is a GuardLink System? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DG Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety Device Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Single Wire Safety (SWS) Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Output Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

GuardLink Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

GuardLink State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

GuardLink Transition from Safe State to Operational State . . . 17

GuardLink Transition from Operational State to Safe State . . . 17

GuardLink Fault Reset Command . . . . . . . . . . . . . . . . . . . . . . . . . . 17

OSSD Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

EMSS Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Guard Locking with GuardLink Systems . . . . . . . . . . . . . . . . . . . . 18

Guard Locking Application Example. . . . . . . . . . . . . . . . . . . . . . . . 19

Chapter 2

GuardLink System Design System Current Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Voltage Drop Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Tap Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Tap Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chapter 3

Installation Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DIN Rail Mounting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Terminal Block Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . 33

Terminal Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Terminal Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Tap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Enclosure Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Taps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Prevent Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Taps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Table of Contents

Chapter 4

Power, Ground, and Wire Wiring Requirements and Recommendation . . . . . . . . . . . . . . . . . . . . 37

DG Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Terminal Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Terminal Assignment and Function. . . . . . . . . . . . . . . . . . . . . . . . . 38

Tap Pin Assignment and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Taps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Multiple Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

DG Safety Relay Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

GuardLink Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Devices with OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Voltage-free Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Single Wire Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

SWS Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Safety Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

13/14 and 23/24 Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Surge Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Chapter 5

Configuration Config/Set Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Configuration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Sel./Save Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Configuration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Configuration Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Delay Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Push Buttons on the Front of DG Safety Relay . . . . . . . . . . . . . . . 54

AOP in the Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . 54

Chapter 6

Status Indicators DG Safety Relay Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Tap Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Chapter 7

Pulse Testing Functions Pulse Testing for Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

EMSS SmartTap Pulse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chapter 8

Opto-link Communications Optical Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Arrangement with 440R-ENETR Interface. . . . . . . . . . . . . . . . . . . . . . 60

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 5

Table of Contents

Chapter 9

440R-ENETR Network Interface

Add-on Profile

Add-on Profile (AOP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Add a 440R-ENETR Interface to the Project . . . . . . . . . . . . . . . . . . . . 61

Add Relays to the 440R-ENETR Interface . . . . . . . . . . . . . . . . . . . . . . 63

Upload Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Manual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Change the Order of the Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Controller Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Select Lock Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

I/O Faulted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Studio 5000 Code Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Lock and Unlock Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

GuardLink Fault Reset Commands . . . . . . . . . . . . . . . . . . . . . . . . . 81

Chapter 10

Safety Function Calculations GuardLink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

SISTEMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Appendix A

Specifications DG Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Appendix B

Configuration Examples Configuration 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Configuration 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Configuration 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Configuration 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Configuration 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Configuration 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Configuration 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Configuration 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Configuration 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Configuration 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Configuration 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Configuration 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Configuration 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Configuration 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Configuration 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Configuration 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Configuration 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Configuration 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Configuration 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Configuration 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

6 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Table of Contents

Appendix C

Regulatory Approvals Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Waste Electrical and Electronic Equipment (WEEE). . . . . . . . . . . . 117

Compliance to European Union Directives. . . . . . . . . . . . . . . . . . . . . 117

Machine Safety Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

DG Safety Relay Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Performance Level/Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Tap Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 7

Preface

This user manual is a reference guide for the GuardLink™ safety system, plug-in

modules, and accessories. It describes the procedures that you use to install,

wire, and troubleshoot your relay. This manual explains how to install and wire

your relay and gives you an overview of the GuardLink safety system

Who Should Use This Manual

Use this manual if you are responsible for the design, installation,

programming, or troubleshooting of control systems that use the GuardLink

safety system.

You must have a basic understanding of electrical circuitry and familiarity with

safety-related control systems. If you do not, obtain the proper training before

using this product.

Summary of Changes

This manual contains new and updated information as indicated in the

following table.

Definitions

Publication AG-7.1 contains a glossary of terms and abbreviations that are

used by Rockwell Automation to describe industrial automation systems. The

following is a list of specific terms and abbreviations that are used in this

manual.

• Electrical Mechanical Safety Switch (EMSS) - A type of tap that

interfaces with safety devices that have redundant voltage-free contacts.

The tap generates pulse tests to detect short circuits to the DC power

supply, short circuits to the DC common, and shorts circuits between

the two contacts.

• GuardLink Control, Lock, and Unlock (CLU) Signal - This signal is

either static or dynamic. When static, this signal is LO when the system

is operational and HI when a demand is placed on the safety system. The

signal is dynamic when an unlock command is issued to Power to

Release guard locking devices.

• GuardLink Operational State - All taps on the GuardLink circuit

indicate that their associated safety device is ready for the machine to

operate.

• GuardLink Safe State - One or more of the taps on the GuardLink

circuit indicate that their associated safety device is not ready for the

machine to operate.

Topic Page

Updated bracket catalog number on front cover Front Cover

Updated the Tap Installation section 34

Updated pin description table for Figure 25

40

Updated the Add Relays to the 440R-ENETR Interface section 63

Added Chapter 10 83

8 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Preface

• GuardLink Safety Signal - A known dynamic safety signal in

operational mode and a two-way communication signal that the DG

safety relay initiates to determine the status of the taps in the safe state.

• HI - The ON state of the output of a logic block or the state of an input

to a logic block or a voltage level to be above the turn-on threshold.

• LO - Logic state of being OFF or a voltage level to be below the turn-off

threshold.

• N/C - No connection

• N.C. (Normally Closed) - A voltage-free electrical contact whose

normal state (that is, no pressure or electrical potential applied) is in the

closed position.

• N.O. (Normally Open) - A voltage-free electrical contact whose

normal state (that is, no pressure or electrical potential applied) is in the

open position.

• Output Signal Switching Device (OSSD)- Generally a pair of solid-

state signals that are pulled up to the DC source supply. The signals are

pulse-tested for short circuits to the DC power supply, short circuits to

the DC common and shorts circuits between the two signals.

• Reaction Time - The time between the true states of one input to the

ON state of the output.

• Recovery Time - The time that is required for the input to be in the LO

state before returning to the HI state.

• Response Time - The time between the trigger of one input to the OFF

state of the output.

• Safety Function - The complete process from sensing the action (for

example, open a safety gate) to executing the final output device (for

example, turning off a pair of contactors).

• Single Wire Safety (SWS) - A unique unidirectional safety-rated signal

that is sent over one wire to indicate a safety status and command the

initiation of a safety function. The SWS can be used in Category 4,

Performance Level e, per ISO 13849-1 and safety integrity level (SIL) 3,

per IEC 62061 and IEC 61508.

• Status Indicators - The status indicators on the front face of the DG

safety relay and the taps are bicolor. Tab le 1

shows how the status

indicators are used in this publication.

Table 1 - Status Indicator State

Symbol Description Symbol Description

Green indicator is OFF

Red indicator is OFF

Green indicator flashes with certain

frequency

Red indicator is OFF

Green indicator is OFF

Red indicator is ON

Green indicator is OFF

Red indicator flashes with certain

frequency

Green indicator is ON

Red indicator is ON

Green indicator flashes with certain

frequency

Red indicator flashes with certain

frequency

Green indicator is ON

Red indicator is OFF

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 9

Preface

• Tap - A connection in a GuardLink circuit that associates a safety device

to the GuardLink circuit.

• Voltage-free Contacts - Electrical contacts that have no voltage that is

applied to them. These contacts are typically N.O. or N.C. contacts that

change state due to a mechanical (for example, someone pressing a push

button) or electromechanical (for example, solenoid operated) stimulus.

Additional Resources

These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page

.

To order paper copies of technical documentation, contact your local

Allen-Bradley distributor or Rockwell Automation sales representative.

Resource Description

NEMA Standard 250 and IEC 60529 Provides explanations of the degrees of protection

that is provided by different types of enclosure.

Industrial Automation Wiring and Grounding Guidelines,

publication 1770-4.1

Provides general guidelines for installing a Rockwell

Automation industrial system.

Product Certifications website, http://

www.rockwellautomation.com/global/certification/

overview.page

Provides declarations of conformity, certificates, and

other certification details.

Industrial Automation Glossary, publication AG-7.1 A glossary of industrial automation terms and

abbreviations.

10 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Preface

Notes:

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 11

Chapter 1

Overview

What Is a GuardLink System?

A GuardLink system is a collection of components to simplify a series

connection of safety devices while achieving the highest industrial safety

rating. The system has these important features:

• Simplifies the connection of series connected safety devices.

• Facilitates the scalability of the safety series connections.

• Provides diagnostic information about each device in the system

without having to run a separate status wire back to the machine control

system.

• Allows the simultaneous or individual lock and unlock of guard locking

interlocks in the series connected system. No need for an additional wire

from the machine control system to lock and unlock the safety gate.

• Helps ease communication to the machine control system over

EtherNet/IP. Communication includes sending non-safety commands

to the devices and receiving status information back from the safety

devices.

Figure 1 on page 12

shows the basic components of a typical application. The

GuardLink tap has M12 quick disconnect terminations to facilitate wiring

with cordsets and patchcords. The DG safety relay can accommodate one or

two GuardLink circuits or a combination of GuardLink and individual safety

devices.

Each GuardLink circuit can accommodate up to 32 taps. The DG safety relay

operates and monitors two safety contactors and has a monitored manual reset.

A typical GuardLink system consists of the following:

• One DG (dual GuardLink) Guardmaster® safety relay (GSR)

• One GuardLink SmartTap for each safety device

• One terminator for each GuardLink circuit

• Patchcords and cordsets

•An optional Ethernet interface

12 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Chapter 1 Overview

Figure 1 - Typical GuardLink System

Taps

Taps create nodes in the GuardLink circuit. A safety device is connected to

each tap. Two types of taps are available:

• Taps that interface with devices having voltage-free safety contacts

• Taps that interface with devices that have OSSD signals

Each type is available in an 8-pin and 5-pin device connection version.

The taps are intended to be mounted on the machine, near the location of the

device it monitors. The different types and versions can be connected in any

order and can be mixed.

R

Each DG safety relay can accommodate

up to two GuardLink circuits, each

containing up to 32 devices.

One DG

safety relay

One GuardLink tap for each

safety device.

One terminator for each

GuardLink circuit.

Cordsets and patchcords

Single Wire Safety for Expansion

Output monitoring

One optional Ethernet interface

(Required if guard locking is used)

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 13

Overview Chapter 1

DG Safety Relay

The DG safety relay is the host of the GuardLink system. By using a sequence

of push buttons on the front face, the DG safety relay can be configured for

many types of safety applications. The DG safety relay can do the following:

• Monitor up to two GuardLink circuits, two safety devices or a

combination

• Use Single Wire Safety (SWS) input and output for expansion

• Execute Stop Categories 0 or 1 (immediate and delayed outputs)

• Monitor the status of output safety devices, like contactors

• Be configured for automatic or monitored manual reset

• Be configured to initiate a lock function for guard locking with a

GuardLink circuit

• Be configured to initiate an unlock function for guard locking with a

GuardLink circuit

Safety Device Inputs

The DG safety device inputs can be configured in one of the following

arrangements:

•One GuardLink circuit

•Two GuardLink circuits

• One GuardLink circuit and one safety device

• Two safety devices

•One safety device

The DG safety relay applies AND logic to all used inputs. Unused inputs are

ignored.

Single Wire Safety (SWS) Input

The DG safety relay then applies AND logic to the SWS input if configured

for use. The single wire safety input is ignored if not included in the

configuration.

Output Monitoring

The DG safety relay monitors the status of external safety output devices. After

all safety inputs are satisfied, the DG safety relay checks the monitoring input

terminal. If 24V is present, the DG safety relay proceeds to execute the reset

function.

14 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Chapter 1 Overview

Reset

The DG safety relay reset function can be applied one of three ways:

• Automatic reset (no connection needed)

• Monitored manual reset by a momentary push button that is connected

to an input terminal

• With an Ethernet interface, the machine control system can initiate the

reset function.

The DG safety relay allows both an input terminal and the machine control

system to perform the monitored manual reset function. The reset signal must

transition from LO to HI and back to LO within a window of 0.25…3 seconds.

The reset occurs on the trailing edge. When using a programmable logic

controller (PLC) to generate the reset signal, use a narrower window

(0.26…2.99 s) for more reliable reset action.

In Figure 2

, the DG safety relay has one GuardLink circuit and one safety

device input. The EtherNet/IP interface reports status information to the

machine control system. The DG safety relay monitors the status of the two

output contactors and uses monitored manual reset to energize the contactors.

Figure 2 - One GuardLink Circuit and One Safety Device

ATTENTION: The reset function must not be used to start or restart the

machine.

R

GuardLink circuit - one tap for each safety device

Safety device (E-stop, mechanical interlock, light curtain,

scanner, OSSD interlocks)

DG safety relay

EtherNet/IP

interface

Output

monitoring

Monitored

Manual

Reset

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 15

Overview Chapter 1

Figure 3 shows an example of a DG safety relay operating as the equivalent of a

DI safety relay. In Figure 3

, the DG safety relay is configured to accept two

input devices, control and monitor two contactors with a manual reset input.

The 440R-ENETR interface reports the status to the machine control system.

The machine control system can also initiate a reset command.

Figure 3 - Two Safety Devices

GuardLink Principle of

Operation

The GuardLink circuit is a continuous chain of safety devices that are

connected in series with only four wires. Two wires provide power and ground

to the taps and devices.

The third wire (GuardLink Safety Signal) performs the diagnostics on the taps

and the devices that are connected to each tap while in the safe state. It also

carries the dynamic safety signal while in an operational state.

The fourth wire (CLU) provides the lock/unlock commands to guard locking

devices on the circuit.

GuardLink State

The GuardLink chain can be in one of four states:

• Initialization

•Safe

•Operational

•Fault

RR

DG safety relay

Two safety devices (E-stops, mechanical interlocks,

light curtains, scanners, OSSD interlocks)

Cordsets or

patchcords

Optional

EtherNet/IP

interface

16 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Chapter 1 Overview

Initialization State

The initialization state starts when power is applied to the GuardLink circuit

and ends when the GuardLink circuit enters the safe state. If no errors exist, the

GuardLink circuit transitions to the safe state; the initialization state cannot

transition to the operational state.

During initialization, the DG safety relay establishes and verifies the validity of

the circuit by checking the following items:

• All devices set their node number

• Not more than 32 devices exist

• The firmware of the taps is compatible with the DG safety relay

firmware.

• The DG safety relay detects node type and position automatically.

When a 440R-ENETR interface is used, it acquires the node types and

positions from the DG safety relay. The 440R-ENETR interface

validates the correct type and position against the setup that is provided

by the Studio 5000® Add-On-Profile (AOP). If validation is not

successful, the 440R-ENETR interface reports an error.

• Validates a terminator is attached to the GuardLink circuit.

Safe State

The GuardLink safety signal commands the DG safety relay to a safe state,

which turns all safety outputs OFF. The GuardLink safety signal monitors the

circuit for changes of state from the taps.

The CLU signal is HI (if guard locking devices are not used) or sending a

dynamic unlock signal (if guard locking devices are used). The taps indicate

this state by a solid red Link indicator.

Operational State

The GuardLink operational state is described as the GuardLink safety signal

that generates a specific dynamic signal to the DG safety relay and the CLU

signal being LO. The state of the DG safety relay safety outputs can be OFF or

ON. The state depends on the configuration, other safety device inputs, the

feedback monitoring input, and the reset input.

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 17

Overview Chapter 1

Fault State

The DG safety relay and the taps have two fault states: recoverable and

non-recoverable. When a fault occurs, the taps and DG safety relay are in a safe

state. Diagnostic information is provided by the indicators. The DG safety

relay also sends diagnostic information to the EtherNet/IP interface.

Recoverable faults can be cleared by cycling the faulted input devices. Non-

recoverable faults require the power to the cycled and can also require

troubleshooting and correction of the fault. When an EtherNet/IP interface is

used, the machine control system can issue a fault reset (equivalent to a power

cycle).

GuardLink Transition from Safe State to Operational State

When the GuardLink signal is in the safe state, the DG safety relay holds the

CLU signal in the high or dynamic unlocking state. The DG safety relay puts

all taps in the safe state. For the GuardLink signal to return to the operational

state, the DG safety relay must know that all taps are ready to go to the

operational state. If the taps are ready to go, the CLU signal is set to LO.

Now that the CLU is set to LO, the last tap generates the safety signal. Each

successive upstream device verifies that the previous device is in a safe state,

confirms that its own device is in a safe state, and sends an inverted safe state

signal to the next device.

When the DG safety relay receives the safety signal, the GuardLink circuit is in

an operational state, and the DG safety relay continues with the evaluation of

the other inputs, output monitoring, and reset inputs.

GuardLink Transition from Operational State to Safe State

Once an input device has a demand on its safety function, the tap stops sending

the safety signal. When the DG safety relay no longer detects the safety signal,

the CLU signal is set to HI to make all taps enter the safe state.

GuardLink Fault Reset Command

Devices with OSSD outputs can sometimes go to a fault state that requires

power cycling. The Ethernet interface can be used to send a fault reset signal

from the machine control system to individual or all devices. This reset signal

cycles the power to the device connected to the specified tap.

18 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Chapter 1 Overview

OSSD Tap

The OSSD tap is designed to specifically interface with safety products that

generate OSSD outputs. The OSSD tap does not perform testing on the

OSSD signals as the input device must perform the test.

The OSSD tap is looking to see if the outputs of the connected device are

energized or de-energized. If the outputs are de-energized, then the tap goes to

a safe state, and the input indicator is red. If the outputs of the device are

energized, then the tap shows a solid or flashing green input indicator.

If the OSSD tap inputs are not the same state for three or more seconds, then

the tap enters a recoverable fault state. Both inputs must go to LO and then

back to HI to recover.

EMSS Tap

The EMSS tap is designed to interface with two voltage-free contacts. The tap

applies 24V to one side of the contact on both channels and looks for the 24V

on the monitoring input. These contacts are pulse tested by the tap, see Pulse

Testing Functions on page 57 for pulse details.

The tap is looking to see if both contacts are closed or open. When the contacts

open, the tap goes to a safe state, and the input indicator is red. When the

contacts close, the tap goes to an operational state, which turns the input

indicator either solid or flashing green.

The EMSS tap has a 10 second simultaneity window. If one contact opens, the

second contact must open within 10 seconds. Similarly, if one contact closes,

the second contact must close within 10 seconds. If the simultaneity window

requirement is not met, the tap goes to a recoverable fault state. To recover,

both contacts must be cycled open and then closed again within 10 seconds.

Guard Locking with GuardLink Systems

Only Power-to-Release guard locking devices can be connected to the

GuardLink taps. When guard locking devices are connected, a 440R-ENETR

interface must be used. The lock and unlock commands can only be issued to

the guard locking devices through the 440R-ENETR interface.

When an unlock request is issued, the DG safety relay turns off OUT X

(terminal X2) immediately and starts the off-delay timer. When the off-delay

timer expires, the DG safety relay issues an unlock command to the GuardLink

circuit and turns off its safety outputs (terminals 13/14 and 23/24).

Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 19

Overview Chapter 1

When multiple guard locking devices are installed on a GuardLink system, the

DG safety relay inserts a short delay between commands to each successive

device to minimize the momentary inrush current to the solenoids. The device

closest to the DG safety relay receives the command first. The device furthest

away from the DG safety relay receives the command last.

The delay between commands is between 135…300 ms. When a few guard

locking devices are used, the delay is 135 ms. As more guard locking devices are

included in the circuit, the delay increases. When 32 guard locking devices are

used, the delay can be up to 300 ms between each device.

Figure 4

shows an example timing diagram. The delay switch is set to

position 5 (1 second delay). The first guard unlocking command starts at

1000 ms. The second unlock signal occurs at 1135 ms. The third unlock signal

occurs at 1270 ms. If 32 guard locking devices are installed, the last one receives

the unlock command at 10,600 ms.

Figure 4 - Unlock Command Timing Diagram

Guard Locking Application Example

Figure 5 on page 20 shows a typical guard locking application example. The

DG safety relay has four taps on the GuardLink circuit:

• First tap — SensaGuard™ integrated-latch interlock switch

• Second tap — 440G-LZ guard locking interlock switch

• Third tap — TLS –ZR guard locking switch

• Fourth tap — SensaGuard flat-pack interlock switch

The TIME switch on the DG safety relay is set to position 9, which provides a

5 second delay to allow the motor to coast to a full stop.

1270 1405 1540 10,600113510000

1

2

3

4

5

32

Unlock Commands to

Guard Locking Devices

Time [ms]

Unlock Request

OUT X (X2)

OUT (13/14, 23/24)

20 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

Chapter 1 Overview

The SensaGuard switches allow immediate access to the machine. Additional

risk reduction measures must be provided to prevent access to the hazards

during the timing period.

Because guard locking is used, a 440R-ENETR interface must be included in

the application. The unlock and lock control commands are initiated by an

HMI and PLC. The PLC sends the command to the 440R-ENETR interface.

Over the optical bus, the 440R-ENETR interface instructs the DG safety relay

to generate the unlock and lock commands through the GuardLink circuit.

The DG and EM safety relays report status information over the optical bus

back to the PLC through the 440R-ENETR interface.

Figure 5 - Guard Locking Application Example Schematic and Logic

Table 2 - Guard Locking Application Example Configuration

A1

L12

X32

L11 34

13 23 33 43

4414 24A2

EM

440R-EM4R2

0

.

2

.

4

.

6

.

8

.

1

0

.

1

2

.

1

4

.

9

INPUT

+24V DC

Ethernet

Host PC

Ethernet

24V DC Com

Reset

Stop

Start

Feedback

100S

Contactors

Immediate

Acting

Loads

A1

S32 14S42

13 23

24

S11 S12S21 S22

X2

X3

X4

X1 A2

DG

440R-DG2R2T

OUT X

SWS

PLCHMI

L1

L2 L3

M

K1

K2

+

440R-ENETR

A

B

C

TIME

440N-Z21SS3PH

SensaGuard

Interlock

898D-418U-DM2

Terminator

440N-Z21SS2JN9

SensaGuard

Interlock

INPUT INPUT

440G-LZS21SPRH

Guard Locking

Safety Switch

INPUT

440S-SF8D 440S-SF8D

440S-SF8D

440G-TZS21UPRH

Guard Locking

Safety Switch

L

++

N

1606-XLP95E

24-

28V

DC ok

K2

K1

440S-SF5D

K1 K2

Status Status

Control

Schematic Logic

OUT X OUT 14/24

SMF Level

LOGIC Level

SOF Level

FBFB

RR

IN 1

Indicator Function Configuration ID: 0x6A

OUT Safety Functions IN1

IN 1 Input Type GuardLink

IN 2 Input Type Not used

OUT X Output Type SWS

IN X Input Mode SWS Disabled

Reset Reset Type Monitored Manual

FB Reset Assignment SOF

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